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Centrifugal Compressors in Hydrocarbon Processing Industries

A Comprehensive Engineering Overview

  • 2025
  • Book
Author
Neetin Ghaisas
Publisher
Springer Nature Switzerland
Part of
Springer Professional "Business + Economics & Engineering + Technology"
Springer Professional "Engineering + Technology"
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About this book

This book offers a unique perspective on the aerodynamic and mechanical design features of centrifugal compressors. It provides detailed explanations of auxiliary systems to support engineering professionals involved in the specification, application, and selection of compression strings and packages.

The book covers the fundamentals of centrifugal compressor casing and internal design, complemented by in-depth analysis of impellers and rotors. Chapters on surge detection and control, couplings, dry gas seals and their support systems, and lubrication oil systems provide a comprehensive understanding of the underlying theory, operational principles, and design processes.

Topics such as lateral rotordynamics, advanced torsional analysis, shop testing, specialized engineering analyses, and condition monitoring address key knowledge-based engineering parameters. These are essential for achieving industry-standard-compliant designs, optimal performance, safety, and long-term reliability in service.

In addition to discussing conventional concrete foundations, the chapter on machinery modularization introduces innovative installation strategies. These include shifting significant portions of site work to module yards, reducing material movement at job sites, and lowering costs associated with construction and pre-commissioning activities. Machinery and process modules contribute to optimized plot layouts, ultimately reducing the total installed cost of process plant facilities.

Comprehensive and detailed technical specifications for inquiries and purchases aim to eliminate guesswork, misinterpretation, and scope gaps. Errors or omissions in purchase orders can be costly and difficult to rectify during project execution. The chapter on compressor specifications, proposal evaluation, and design coordination addresses these challenges using real-world examples.

In light of global initiatives to reduce greenhouse gas emissions, a dedicated chapter explores the process of capturing and storing carbon dioxide (CO₂). It discusses the two primary compressor types used for CO₂ compression, provides an overview of sequestration processes and current challenges, and highlights new technologies that extend the life of compressor materials. Configuration options for improved overall efficiency are also examined.

Table of Contents

Frontmatter
Chapter 1. Compressor Casings
Abstract
A centrifugal compressor casing houses both stationary and rotating internal components. Stationary elements include the inlet volute, guide vanes, discharge volute, diaphragms, return channels, sealing systems, and bearings. The dynamic assembly—referred to as the rotor—comprises the shaft, impellers, and balance drum (or piston). Process nozzles are either welded onto the casing or integrally cast as part of its structure, and provisions are also made for auxiliary piping connections. This chapter offers an in-depth exploration of casing joint types and their pressure-handling capabilities, various casing configurations, shear ring designs specific to radially split compressors, and the methods used in casing fabrication. Additional topics covered include the interface between the casing and its mounting pedestal, design considerations for discharge volutes and nozzle configurations, and the role of water or oil injection in compressor operation.
Neetin Ghaisas
Chapter 2. Rotor Design
Abstract
This chapter provides a comprehensive overview of rotor design principles for centrifugal compressors. The rotating assembly comprises several key components, including the shaft, impellers, sleeves, balance piston(s), thrust disk, and coupling hubs. Shaft design is guided by both lateral and torsional rotordynamic behavior, as well as its role in transmitting torque to the impellers and any additional casings located at the nondrive end. Material selection for the rotor assembly is influenced by factors such as process gas composition, operating and design parameters, and the installation environment. This chapter outlines a systematic approach to rotor design, examining how shaft length and diameter affect rotordynamic performance, and comparing stiff versus flexible shaft configurations along with their respective applications. It also covers shaft manufacturing techniques and commonly used materials. Additional topics explored in detail include impeller thrust forces, sizing criteria for balance pistons, the types of interstage and balance piston seals, interference fits on the shaft, and protective surface treatments for rotor components.
Neetin Ghaisas
Chapter 3. Impellers
Abstract
This chapter presents its content in a list-based format, focusing on key concepts related to thermodynamics, aerodynamics, stage design, curve profiles, performance maps, and specific speed as they pertain to centrifugal compressor impellers. These topics are supported by illustrative figures to aid in the explanation and comprehension of fundamental principles. While quantitative data such as typical ranges and values for impeller aerodynamic design can be found extensively in existing literature, this chapter opts for a qualitative approach to the subject matter. Additionally, it offers a detailed overview of how inlet condition variations, surge and stonewall phenomena, impeller manufacturing techniques, standard materials, material selection criteria, and operational stresses influence overall compressor performance.
Neetin Ghaisas
Chapter 4. Antisurge and Performance Control Systems
Abstract
Surge detection and control in centrifugal compressors are inherently complex functions that demand specialized knowledge and expertise in machinery dynamics, control systems, and process behavior. Achieving effective control involves the development of sophisticated algorithms, robust fallback mechanisms, and custom-engineered systems capable of executing high-speed computations for optimal turbomachinery performance. This chapter outlines the foundational concepts, including the dynamic compressor map, operating envelope, surge cycle characteristics, and methods for surge detection. It further explores the roles of antisurge and performance controllers within a comprehensive control strategy, detailing antisurge response mechanisms and advanced control functionalities such as loop decoupling, load sharing, performance override, limiting loops, and fallback operations. Additionally, the chapter addresses key design and operational considerations for recycle piping and valve sizing, hot-gas bypass valve specifications, and instrumentation requirements critical to reliable surge management.
Neetin Ghaisas
Chapter 5. Dry Gas Seals
Abstract
Dry gas seals play a critical role in the performance of modern centrifugal compressors. However, specifying engineers often overlook the importance of clearly defining the scope and carefully selecting the most suitable seal type, its control system, and associated auxiliaries for the intended application. Instead, this responsibility is frequently deferred to compressor manufacturers, who make these selections based on their own standards. To ensure optimal design and performance, several key factors must be thoroughly evaluated—these include the gas composition, the thermodynamic properties of the seal or buffer gas, the choice of barrier gas, operational scenarios such as slow roll conditions, compatibility with bidirectional rotation, and overall system rating. Ideally, this evaluation should be a collaborative effort involving the equipment vendor, the seal manufacturer, and machinery engineers representing both the owner and the engineering contractor. Choosing the correct dry gas seal and its support system is essential for ensuring the long-term reliability and availability of centrifugal compressor trains in process plants. This chapter explores several important aspects, including the operating principles of dry gas seal faces, techniques for controlling seal gas, procedures for slow rolling, and strategies for managing demanding sealing environments.
Neetin Ghaisas
Chapter 6. Seal Gas Treatment
Abstract
Dry gas seals serve as a highly effective, dependable, and resilient sealing solution for compressors operating across a wide range of applications in the petrochemical, natural gas, and petroleum sectors. Their optimal performance hinges on a continuous, uninterrupted supply of clean and dry seal gas delivered within the specified flow and pressure parameters. This ensures proper lift-off of the seal faces, minimizing wear and maximizing efficiency. Both pressurized and unpressurized configurations rely on clean, dry seal gas introduced upstream of the seal to form a protective barrier against contamination from the process stream. Seal gas treatment involves the removal of particulates and aerosols to maintain purity. Dedicated seal gas support systems are engineered to deliver the required flow rate, temperature, and pressure, with these variables actively monitored and controlled. This chapter provides a qualitative overview of critical subsystems—such as dew-point management and pressure boosting—that contribute to the reliability and performance of dry gas seals.
Neetin Ghaisas
Chapter 7. Lubricating Oil Systems
Abstract
Lubricating oil systems play a critical role in ensuring the efficient operation, long-term reliability, and overall availability of turbomachinery trains (or strings). Any shortcomings in their design can lead to suboptimal performance and compromise not only the oil system itself but also the reliability and functionality of the entire equipment train it supports. To ensure optimal performance, the scope and configuration of the lubricating oil system for a given application should be collaboratively assessed by the responsible equipment vendor, the oil system designer, and the specifying machinery engineer. A thorough review of all system components is essential, and the design basis should be agreed upon by all parties as early as possible—ideally before the purchase order is issued. This chapter explores the key considerations for selecting and sizing the components that make up a pressurized lubricating oil system for modern turbomachinery strings. The design principles outlined are broadly applicable to oil systems serving a variety of driven and driving equipment types.
Neetin Ghaisas
Chapter 8. Flexible-Element Couplings
Abstract
Couplings are essential components in machinery trains, yet they are often overlooked during the specification process by engineering contractors and owner companies. In many cases, users base their selection solely on basic parameters such as operating speed, torque, safety factor, and shaft dimensions. However, a comprehensive evaluation should also include additional critical factors—such as combined steady-state and cyclic stresses, angular misalignment tolerance, torsional rigidity, axial displacement capacity, axial natural frequencies, anticipated peak and transient torques, and both lateral and torsional critical speeds. To ensure a well-informed selection, this evaluation should be a collaborative effort involving the primary equipment vendor, subvendors for the driver and gear units (if applicable), the owner’s machinery engineers, and the engineering contractor. Choosing the appropriate coupling is a key contributor to the long-term reliability and operational availability of machinery trains in process plants. This chapter highlights two of the most commonly used high-performance, non-lubricated coupling types in modern centrifugal compressor trains: metal diaphragm couplings and disk-pack couplings. It also covers standard selection methodologies, typical construction materials, balancing practices, torque monitoring strategies, and coupling guard design considerations.
Neetin Ghaisas
Chapter 9. Shop Tests and Special Engineering Analyses
Abstract
During the manufacturing of centrifugal compressors, numerous in-process examinations, inspections, and testing activities are conducted. Among these, the shop performance test and the mechanical running test hold particular importance for customers. The performance test serves as a key indicator of the compressor’s actual thermodynamic efficiency and mechanical behavior, and helps validate the engineering design and analysis. The results from this test are instrumental in defining the head-capacity curve—its shape and limits—marked by surge at low flow rates and stonewall or stall at high flow rates. This chapter outlines the proper approach to scoping, planning, and executing both performance and mechanical running tests within the compressor manufacturer’s facility. It includes a sample calculation demonstrating how to convert data from test at a certified point into predicted performance under specified operating conditions. Additionally, it covers specialized analyses required by certain users for large-scale compressors.
Neetin Ghaisas
Chapter 10. Grouting
Abstract
The reliability of plant equipment plays a pivotal role in determining the profitability of industrial and manufacturing operations. Modern petroleum, petrochemical, and gas processing facilities rely on a wide array of rotating machinery used in both general-purpose and specialized process applications. Leading companies that operate dynamic equipment consistently aim to enhance efficiency and reliability, thereby reducing operational costs and boosting overall productivity—both of which directly benefit the bottom line. Long-term equipment reliability is influenced not only by the rotating machines themselves but also by associated piping, auxiliary systems, mounting methods, grouting, anchoring, and foundation design. Achieving optimal performance requires comprehensive engineering, stringent specifications, careful equipment selection, and adherence to best practices throughout design, manufacturing, installation, operation, and maintenance. Grouting, particularly epoxy grout, is a fundamental element of the equipment system. It establishes a monolithic bond between machinery and its foundation, ensuring effective load transfer, energy dissipation, and vibration damping. The importance of proper grouting in enhancing equipment performance, reliability, and minimizing life-cycle costs cannot be overemphasized.
Neetin Ghaisas
Chapter 11. Modularization
Abstract
A module refers to a transportable unit composed of preassembled components from a process plant. The modularization approach aims to streamline facility layouts and shift a substantial portion of construction activities from the field to dedicated module yards, thereby minimizing on-site labor. In highly modularized setups, both small and large static equipment, as well as rotating machinery packages, are typically mounted on steel frameworks. A key element of modularization is the integration of equipment into these modules. Installing rotating or reciprocating machines on steel structures—rather than traditional concrete foundations—introduces distinct engineering challenges. Fabricated steel modules possess lower stiffness and damping characteristics compared to concrete, making it essential to assess how these structural properties affect the performance of mounted machinery. This requires specialized analytical techniques and tailored design strategies. This chapter explores the principles of modularization, various module types, structural configurations and loading conditions, and the methodologies used for structural analysis of modules.
Neetin Ghaisas
Chapter 12. Lateral Rotordynamics
Abstract
Rotating equipment plays a vital role across a wide range of industries, including oil and gas, refining, manufacturing, and chemical processing. Commonly referred to as turbomachinery, these systems encompass steam turbines, gas turbines, electric motors, and compressors. Many of these machines are essential to core operations and often run continuously for extended periods—sometimes years—before scheduled maintenance or downtime occurs. Any interruption in their operation can have a substantial impact on both productivity and financial performance. As industries demand greater power output, improved efficiency, reduced costs, and more compact designs, turbomachinery engineering has had to evolve rapidly. This evolution has driven the development of advanced analytical tools and more sophisticated design methodologies. Consequently, ensuring high reliability in these machines is not just desirable—it’s imperative. This chapter aims to present a broad overview of rotordynamics, focusing on the physical principles behind the subject while avoiding deep theoretical detail.
Neetin Ghaisas
Chapter 13. Torsional Analysis
Abstract
This chapter presents a practical approach to torsional analysis. It covers fundamental techniques for determining the stiffness and inertia of mechanical components. Examples range from basic two-mass and three-mass systems to more intricate configurations that require computer-based modeling. The chapter also explores the transient response of torsional systems under forced conditions, such as during synchronous motor startup and short-circuit scenarios. Fatigue assessment methods and life expectancy projections are examined in detail. Given the complexity of torsional issues, theoretical models often need validation through real-world measurements. This approach enhances the reliability of system modifications and ensures machinery is engineered for safe and effective operation.
Neetin Ghaisas
Chapter 14. Condition Monitoring and Diagnostics
Abstract
Vibration monitoring has long been recognized as a reliable method for safeguarding compressor trains. Modern monitoring systems not only offer protection but also incorporate advanced features for diagnostics and condition assessment. This chapter explores how condition monitoring technologies are applied to compressors, with particular emphasis on vibration monitoring as a key diagnostic and analytical tool. While other techniques are briefly discussed, they may hold equal significance within a comprehensive condition monitoring strategy. The chapter presents a high-level overview of this expansive subject, intentionally omitting detailed and specialized content for the sake of brevity.
Neetin Ghaisas
Chapter 15. Preservation and Packaging
Abstract
This chapter outlines the minimum requirements for preserving and packaging compression equipment to maintain its integrity from the point of origin through transit and post-delivery. Packaging and preservation methods are determined by several factors, including the storage location at the jobsite—whether in a climate-controlled indoor facility or an outdoor area exposed or shaded—the site’s ambient temperature range, and the expected duration of storage prior to installation. The preservation process aims to protect the equipment from contamination, corrosion, and physical damage caused by environmental elements such as dust, sand, humidity, sunlight, and rain. To facilitate efficient handling upon arrival, all items must be clearly tagged for identification. Additionally, shipping cards for each component should include the part number, description, purchase order number, line-item reference, quantity, and any other details required.
Neetin Ghaisas
Chapter 16. Compressor Specification, Evaluation, and Design Coordination
Abstract
Thorough and well-defined technical specifications for equipment inquiries and procurement are essential to avoid ambiguity, misinterpretation, and scope gaps. Incomplete or inaccurate purchase orders can lead to significant costs and complications during project execution. To mitigate these risks, experienced and knowledgeable machinery engineers should develop comprehensive technical requisitions that clearly outline relevant project specifications, applicable industry standards and codes, local regulatory requirements, inspection protocols, specialized analyses and testing procedures, spare parts provisions, and vendor documentation. This chapter illustrates the subject through three detailed scope narratives: one for a motor-gear-driven centrifugal compressor string, one focused on evaluating technical proposals, and another addressing design coordination with equipment manufacturers.
Neetin Ghaisas
Chapter 17. CO2 Compressors
Abstract
Anthropogenic CO2 emissions from the combustion of fossil fuels and various industrial activities are a primary driver of global warming and its related climate impacts. To address this challenge, carbon capture, utilization, and storage (CCUS) technologies play a vital role in global decarbonization strategies. A range of commercially available carbon capture solutions exist, each adaptable to specific CO2 recovery applications. Once captured and purified, CO2 must be compressed for efficient transport, further processing, and long-term storage. This chapter provides a comprehensive overview of key CCUS considerations, including the context of global decarbonization initiatives, CO2 product requirements, available capture technologies, and the unique thermodynamic challenges associated with CO2 compression. It also explores the mechanical design aspects, common construction materials, compressor train configurations, shaft sealing techniques, capacity control methods, and modular design strategies for the two predominant types of CO2 compressors: centrifugal and integrally geared.
Neetin Ghaisas
Backmatter
Title
Centrifugal Compressors in Hydrocarbon Processing Industries
Author
Neetin Ghaisas
Copyright Year
2025
Electronic ISBN
978-3-032-03687-2
Print ISBN
978-3-032-03686-5
DOI
https://doi.org/10.1007/978-3-032-03687-2

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